Adjustment Plate Gauge Insert and Adapter for Hands-Free Lock Installation

ABSTRACT

A door lock chassis has a gauge insert that defines different dimensions corresponding to different door thicknesses. The gauge insert is positionable in the lock chassis in different orientations corresponding to the different dimensions used to align the lock chassis for different door thicknesses. Additionally, a door lock may include an anti-rotation assembly for preventing rotation of the lock chassis. The anti-rotation assembly may include a retention member that is secured to an inside hub of a lock chassis. As an anti-rotation member is displaced in a first axial direction along the inside hub to a mount position, the anti-rotational member may deflect resilient members of the retention member. With the anti-rotation member at the mounted position, the anti-rotation member may be in a frictional engagement with the previously deflected resilient members so that anti-rotation member is retained at the mount position.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/793,214, filed Mar. 15, 2013, which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present application relates to cylindrical locksets and moreparticularly, but not exclusively, to the installation of such locksetsin doors of varying thickness.

BACKGROUND

Cylindrical locksets typically include a cylindrical lock chassis havinga transverse centerline. During installation, regardless of thethickness of the door in which the lockset is being installed, thetransverse centerline of the lock chassis should usually coincide withthe centerline of the door thickness. If this installation criterion isnot met, the lockset may fail to function properly. Therefore, a lockchassis may have an adjustable configuration that allows the lockchassis to be appropriately aligned with a variety of door thicknesses.For example, the position of the lock body relative to an associatedmounting plate or mounting flange may be adjustable. Yet, difficultiesin making accurate assessments of the current door thickness setting, orof distinguishing between alternative settings, can lead to use ofincorrect settings and wasted effort. Likewise, the occurrence ofinadvertent changes from factory preset conditions during shipping orhandling can lead to errors or necessitate additional steps ofvalidation and correction.

Cylindrical locksets may also have an installation step in which ananti-rotation plate or other securing member is placed over the lockchassis, held into place by the installer's hand, and then secured tothe door by suitable screws or bolts. If the anti-rotation member orsecuring member is not held in place by the installer's hand, theanti-rotation member may slide off from the lock chassis, causing delayand wasted effort. Conversely, if the installer holds the securingmember in place, then one or both of the installer's hands are occupiedand thus the installer is less free to install remaining components ofthe lockset.

BRIEF SUMMARY

Embodiments of the present invention provide a door lock chassis havinga gauge insert that defines different dimensions corresponding todifferent door thicknesses such that, when the gauge insert is insertedinto the door lock chassis at a particular orientation, a dimension ofthe gauge insert corresponding to that orientation aids in adjusting thelock chassis for an associated door thickness. Moreover, according tocertain embodiments, the gauge insert has multiple dimensions where eachdimension corresponds to a different door thickness and, when properlyoriented, can correctly align the lock chassis for that particular doorthickness. Additionally, according to certain embodiments, the lockchassis has a retention mechanism that retains an anti-rotation memberon the lock chassis so that an installer is free from having to hold theanti-rotation member or plate on the lock chassis in subsequent assemblyprocedures. The retention mechanism is received into a lock chassishousing and does not require screws, bolts, or the like to retain theanti-rotation member to a lock chassis during assembly of the lockmechanism.

Additionally, an aspect of the present invention is a door lock chassisthat is adapted to be mounted within doors having different thicknesses.The door lock chassis includes a lock body and an adjustment plate thatis adapted to be adjustably mounted to the lock body. The door lockchassis also includes a removable gauge insert that is adapted tofrictionally engage the adjustment plate and to be received in the slotat one of a plurality of positive stop arrangements. Further, each ofthe plurality of positive stop arrangements are configured to, when theadjustment plate is operably mounted to the lock body, separate theadjustment plate from a portion of the lock body by an axial distance.Additionally, the axial distance is different for each of the pluralityof positive stop arrangements.

Another aspect of the present invention is a door lock chassis that isadapted to be mounted within doors having different door thicknesses.The door lock chassis includes a body portion having at least one slotand an adjustment plate that is adapted to be adjustably mounted to thelock body. Further, the at least one gauge insert is adapted to beremovably received in the at least one slot and a first portion and asecond portion. The first portion is adapted to provide an axialposition for the adjustment plate relative to at least the body portion.The second portion is adapted to frictionally engage the adjustmentplate so as to resist movement of the adjustment plate away from theaxial position.

Another aspect of the present invention is an anti-rotational assemblyfor a door lock having a lock chassis. The anti-rotational assemblyincludes an inside hub of the lock chassis that has a receptacle thatincludes a cavity and a pair of channels. The pair of channels areconfigured to longitudinally extend along opposing sides of the cavity.The anti-rotational assembly also includes a retention member that has abase and one or more resilient members. The base has a pair of lips thatare adapted to be slidingly received in the pair of channels.Additionally, the anti-rotational assembly includes an anti-rotationmember that is configured for a sliding engagement with the one or moreresilient members in a first axial direction as the anti-rotation memberis displaced to an mount position relative to the inside hub. Theanti-rotation member is also configured for a frictional engagement withthe one or more resilient members to retain the anti-rotation member inthe mount position.

Additionally, a further aspect of the present invention is ananti-rotational assembly for a door lock having a lock body. Theanti-rotational assembly includes an inside hub of the lock body thathas an outer section. The anti-rotational assembly also includes aretention mechanism that is secured to the inside hub and which has oneor more resilient members. The anti-rotation member is configured todeflect the one or more resilient members as the anti-rotation member isdisplaced in a first axial direction, and to be retained in a mountposition on the inside hub by a frictional engagement with the one ormore resilient members.

Other aspects of the present invention will become apparent byconsideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates an exploded perspective view of a cylindrical typelock assembly according to an embodiment of the present invention thatis installed in a door.

FIG. 2 illustrates an exploded perspective view of a lock chassis for alock assembly according to an embodiment of the present invention.

FIG. 3 illustrates a perspective view of the lock chassis shown in FIG.2.

FIG. 4 illustrates an end elevational view of the lock chassis shown inFIG. 2.

FIG. 5 illustrates a cross sectional view of a lock chassis 2 as takenalong the line 5-5 in FIG. 4.

FIG. 6 illustrates an end elevational view of the lock chassis shown inFIG. 4 and includes an anti-rotation plate that is positioned on thelock chassis.

FIG. 7 illustrates a cross sectional view of a lock chassis and ananti-rotation plate as taken along line 7-7 in FIG. 6.

FIG. 8 is an exploded perspective view of a retention member and aninside hub of the lock chassis shown in FIG. 2.

FIG. 9 is a side elevational view of a gauge insert of the lock chassisshown in FIG. 2.

The foregoing summary, as well as the following detailed description ofcertain embodiments of the present invention, will be better understoodwhen read in conjunction with the appended drawings. For the purpose ofillustrating the invention, there is shown in the drawings, certainembodiments. It should be understood, however, that the presentinvention is not limited to the arrangements and instrumentalities shownin the attached drawings.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

While the present invention can take many different forms, for thepurpose of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended. Any alterations and further modificationsof the described embodiments, and any further applications of theprinciples of the invention as described herein, are contemplated aswould normally occur to one skilled in the art to which the inventionrelates.

Turning to the figures, FIG. 2 is an exploded view of an adjustable lockchassis 10 according to an embodiment, and FIG. 1 is an exploded view ofthe installation of a lock assembly 15, which includes the lock chassis10, in a door 100. The door 100 has a cylindrical hole 104 and twosmaller mounting holes 106 that extend through the thickness of the doorfrom the inside face 101 to the outside face 102. The door 100 also hasa latch hole 108 that extends from the side edge of the door 100 to thecylindrical hole 104.

The lock chassis 10 includes a body portion 17 comprising an outsidehousing 38 and an inside hub 48, and a slide assembly 43 including aslide 44 and a slide clip 45. The slide assembly 43 is located in a slot41 of the outside housing 38. An outside spindle 40 and key cam assembly42 are rotably captured in the outside housing 38 so as to be inoperable engagement with an outside portion of the slide assembly 43. Aninside spindle 46 is rotably captured in the inside hub 48 so as to bein operable engagement with the inside of the slide assembly 43. Theinside hub 48 is secured to the outside housing 38 via mounting screws49.

In the illustrated embodiment, the lock chassis 10 includes anadjustment plate 36, which includes an annular portion 36 a and a flange36 b. The annular portion 36 a has interior threads and is threaded onthe outside portion 39 of outside housing 38 which is provided withexterior threads. A gauge insert 60 to be described in greater detailbelow is positioned within a slot 62 of the outside housing 38. As shownin FIG. 3, a positive stop 65 a of the gauge insert 60 contacts aninside edge 36 c of the annular portion 36 a of the adjustment plate 36in a positive stop arrangement indicative of a proper axial position ofthe adjustment plate 36 for a corresponding door thickness.

As shown in the FIG. 5 embodiment, a leg 63 of the gauge insert 60frictionally engages the interior threads of the annular portion 36 a ofthe adjustment plate 36. This frictional engagement provides resistanceagainst rotation of the adjustment plate 36, which reduces the chancethat the position of the adjustment plate 36 is inadvertently changed.

Referencing FIGS. 1 and 2, during assembly of the lock assembly 15, thelatch 34 is first positioned in the latch hole 108 so as to have thetail piece 34 a extending into the cylindrical hole 104. Then, the lockchassis 10 is inserted into the cylindrical hole 104 such that the tailpiece 34 a of the latch 34 engages the engagement part 44 a of the slideassembly 43 of the lock chassis 10. Flange 36 b rests against theoutside face 102 of the door 100 and has slots 37 aligned with themounting holes 106 in the door 100. An anti-rotation plate 22, which hasan interior opening 20 shaped to correspond to the shape of an outsidesection 30 of the inside hub 48, is placed over the outside section 30.Flange 22 b of the anti-rotation plate 22 rests against the inside face101 of the door 100 and has slots 21 aligned with the mounting holes 106of the door 100.

FIG. 2 shows an example of a retention member 50, which will bedescribed in greater detail below. The retention member 50 is providedbetween the outside section 30 of the inside hub 48 of the lock chassis10 and a surface of the anti-rotation plate 22 so as to capture theanti-rotation plate 22 to the lock chassis 10. This frees an installer'shands to install the remaining portions of the assembly.

Referencing FIG. 1, an outside spring cage assembly 12 has an integratedspindle 13 that fits over the outside spindle 40 of the lock chassis 10.Internal slots of the integrated spindle 13 engage correspondingprojections in the outside spindle 40 such that the integrated spindle13 and outside spindle 40 are rotationally coupled. An outside handle 18mounts to the end of the integrated spindle 13. A key cylinder 16extends through the integrated spindle 13 to operate the key camassembly 42. An outside rose 14 is attached to the outside spring cageassembly 12.

The outside spring cage assembly 12 includes threaded bosses 11 whichextend through the slots 37 of the flange 36 b and into the mountingholes 106 of the door 100. Mounting screws 32 extend through themounting holes of the inside spring cage assembly 24, the slots 21 ofthe anti-rotation plate 22, and the mounting holes 106 of the door 100,where the mounting screws 32 are threaded into the threaded bosses 11 ofthe outside spring cage assembly 12. An inside handle 28 is attached tothe end of a spindle 25 of the inside spring cage assembly 24. A rose 26is attached to the inside spring cage assembly 24. A suitable plungerassembly (not shown) may be provided to couple the thumb turn button ofthe inside handle 28 to the key cam assembly 42 of the lock chassis 10.

Referring now to FIGS. 2-5 and 9, according to certain embodiments, thegauge insert 60 is generally rectangular shape and has a longitudinalaxis L that is parallel to the axis of rotation R of the door handle 18.However, the gauge insert 60 may have a variety of different shapes andsizes, such as, for example, being triangular or hexagonal, among othershapes. Additionally, the gauge insert 60 may be constructed from avariety of different materials, including, for example, plastic andrubber, among other materials.

The illustrated gauge insert 60 has four different longitudinaldimensions D1, D2, D3, D4 that are configured to accommodate doors 100of different thicknesses. Moreover, the gauge insert 60 is removablypositionable in the slot 62 of the lock chassis 10 in differentorientations. The different orientations serve to align the lock chassis10 at the correct position within the door 100. The correct position ofthe lock chassis 10 within the door 100 may be determined, for example,in the illustrated embodiment by the relative position of the adjustmentplate 36 on the body portion 17 of the lock chassis 10. Such alignmentis accomplished by providing a positive indicia or positive stop for theadjustment plate 36. The illustrated gauge insert 60 has four suchpositive stops 65 a, 65 b, 65 c, 65 d, with each positive stop 65 a, 65b, 65 c, 65 d, respectively, corresponding an associated longitudinaldimension D1, D2, D3, D4.

In the embodiment illustrated in FIG. 9, the longitudinal dimensions D1,D2, D3, D4 are determined based on the distance of the associatedpositive stop 65 a, 65 b, 65 c, 65 d from an end 69 a, 69 b of a remote,non-adjacent leg 61, 63 of the gauge insert 60. Thus, for example, thefirst longitudinal dimension Dl extends from the end 69 a of the firstleg 61 to the first positive stop 65 a, while the second longitudinaldimension D2 extends from the end 69 b of the second leg 63 to thesecond positive stop 65 b.

Referencing FIGS. 2, 3 and 5, according to the illustrated embodiment,the slot 62 of the lock chassis 10 is positioned in the periphery of theouter portion 39 of the outside housing 38 of the lock chassis 10.Further, according to certain embodiments, the length of the slot 62 islonger than the length of the gauge insert 60. The slot 62 defines twoupper receiving portions 62 a and 62 c, and a lower receiving portion 62b disposed longitudinally between the two upper receiving portions 62 a,62 c. The depth of the slot 62 at the lower receiving portion 62 b, asviewed in FIG. 5, is equal to or slightly greater than the height of thepositive stops 65 a, 65 b, 65 c, 65 d. The axial length of the slot 62at the lower receiving portion 62 b is sized to receive the longitudinalportion 68 a of the gauge insert 60 defined between the positive stop 65a and the positive stop 65 b, and to receive the longitudinal portion 68b of the gauge insert 60 defined between the positive stop 65 c and thepositive stop 65 d. When the gauge insert 60 is inserted in the slot 62with the positive stops 65 c and 65 d facing downward into the slot 62and the positive stop 65 a facing the outside (to the left in FIG. 5)and the positive stop 65 b facing the inside (to the right in FIG. 5),the leg 61 of the gauge insert 60 rests on the first upper receivingportion 62 a of the slot 62, and the leg 63 of the gauge insert 60 restson the second upper receiving portion 62 c of the slot 62. Similarly,when the gauge insert 60 is inserted in the slot 62 with the positivestops 65 a and 65 b facing downward into the slot 62 and the positivestop 65 c facing the outside (to the left in FIG. 5) and the positivestop 65 d facing the inside (to the right in FIG. 5), the leg 63 of thegauge insert 60 rests on the first upper receiving portion 62 a of theslot 62, and the leg 61 of the gauge insert 60 rests on the second upperreceiving portion 62 c of the slot 62.

The body portion 17 of the lock chassis 10 provides an inside end wall64 at an end of the slot 62 (upper right of FIG. 5) against which a leg61, 63 of the gauge insert 60 abuts to stop axial movement of the gaugeinsert 60. In the FIG. 5 embodiment, for example, with the gauge insert60 inserted in the slot 62, as the adjustment plate 36 is threaded onthe outside housing 38 the inside edge 36 c of the annular portion 36 aof the adjustment plate 36 contacts the positive stop 65 a and urges thegauge insert 60 axially toward the inside end wall 64 until the leg 61of the gauge insert 60 abuts the inside end wall 64. The gauge insert 60is thus sandwiched between the annular portion 36 a of the adjustmentplate 36 and the inside end wall 64 of the body portion 17 of the lockchassis 10. The positive stop 65 a of the gauge insert 60 functions tostop further axial movement of the adjustment plate 36 and indicates tothe installer that the adjustment plate 36 is in the proper axialposition relative to the body portion 17 of the lock chassis 10 for acorresponding door thickness.

The depth of the slot 62 at the first upper receiving portion 62 a isequal to or slightly greater than the height of the legs 61, 63 of thegauge insert 60. The depth of the slot 62 at the second upper receivingportion 62 c is sized so that when the gauge insert 60 is inserted inthe slot 62 and the annular portion 36 a of the adjustment plate 36 isthreaded on the outside portion 39 of the outside housing 38, at least aportion of the adjustment plate 36, such as the interior threads of theannular portion 36 a thereof, engages the leg 61, 63 of the gauge insert60 (leg 63 in the as shown embodiment of FIG. 5) resting on the upperreceiving portion 62 c. This engagement, which according to theillustrated embodiment is a frictional engagement, provides resistanceagainst rotation of the adjustment plate 36, and reduces the chance thatthe position of the adjustment plate 36 is inadvertently changed. Asshown in FIG. 9, lead-in chamfers 71, 73 can be provided at the distalends of the legs 61, 63 to facilitate easier and more gradual threadingengagement of the legs 61, 63 by the annular portion 36 a of theadjustment plate 36. As such, the torque required to thread theadjustment plate 36 onto the outside portion 39 of the outside housing38 increases only gradually, so that, for example, the installer canrecognize that the adjustment plate 36 has not reached a stop. When theannular portion 36 a of the adjustment plate 36 encounters a stop, forexample the first positive stop 65 a in FIG. 5, the positive stop 65 acan serve as an indication that the correct door thickness setting hasbeen reached.

As shown in FIG. 9, the positive stops 65 a, 65 b, 65 c, 65 d, of theillustrated gauge insert 60 are each different from the other. Referringto FIGS. 3 and 5, when the gauge insert 60 is inserted in the slot 62 ofthe lock chassis 10 in a first orientation corresponding to thedimension D1, the first positive stop 65 a corresponding to a first doorthickness acts as an indicator. Thus, as shown in FIGS. 3 and 5, thefirst positive stop 65 a serves as an indicator as to where threading ofthe annular portion 36 a of the adjustment plate 36 onto the bodyportion 17 of the lock chassis 10 is to be stopped to obtain an axialposition of the adjustment plate 36 relative to the body portion 17 thatcorresponds to the first door thickness. When the gauge insert 60 isinserted in a second orientation corresponding to the dimension D2, thesecond positive stop 65 b corresponding to a second door thickness actsas an indicator. When the gauge insert 60 is inserted in a thirdorientation corresponding to the dimension D3, the third positive stop65 c corresponding to a third door thickness acts as an indicator. Whenthe gauge insert 60 is inserted in a fourth orientation corresponding tothe dimension D4, the fourth positive stop 65 d corresponding to afourth door thickness acts as an indicator.

The positive stops 65 a, 65 b, 65 c, 65 d, may be provided with suitableindicia to indicate correspondence to for example a default doorthickness, a minimum door thickness, or a maximum door thickness. Forexample, as shown in FIGS. 3 and 9, the positive stop 65 a has a shape75, namely a somewhat arrow shape 75, that is different from the shape,namely a somewhat rectangular shape, of the other positive stops 65 b,65 c, 65 d. The arrow shape 75 can provide a visual indication that, forexample, the positive stop 65 a is a default orientation formanufacturing assembly, and/or that the gauge insert 60 has beencorrectly oriented during the assembly process. Alternatively, theindicia for the positive stops 65 a, 65 b, 65 c, 65 d may list actualdoor thicknesses for each of the stops 65 a, 65 b, 65 c, 65 d, such as,for example, indicia visually indicating or representing 1¾ inches, 1⅝inches, 2 inches, and 2⅛ inches.

The illustrated embodiment shows a single slot 62 provided in theoutside housing 38 and a gauge insert 60 that can be inserted in theslot 62 in four different orientations corresponding to four differentdoor thicknesses. However, according to certain embodiments, multipleslots 62 may be provided in the outside housing 38, for example in acircumferentially spaced manner, and each slot 62 can have a differentaxial length that corresponds to a respective door thickness. Further,according to certain embodiments, a gauge insert 60 may have a singlelongitudinal dimension. In an embodiment, a single slot 62 may beprovided in the outside housing 38, and multiple gauge inserts 60 may beprovided, and each gauge insert 60 may have a different axial lengththat corresponds to a respective door thickness.

Referring to FIG. 9, in an embodiment, the gauge insert 60 may includeprojections 67 that project from the sides of the gauge insert 60. Theprojections 67 make it easier for the installer to manipulate the gaugeinsert 60 to a desired orientation. Further, when the gauge insert 60 isinserted in the slot 62 of the lock chassis 10 the projections 67function to frictionally engage the side walls of the slot 62 and resistthe gauge insert 60 from being inadvertently dislodged or falling outfrom the slot 62. In an embodiment, the width of the slot 62 may beslightly larger than the width of the gauge insert 60 at thenon-projection portions, and slightly smaller than the width of thegauge insert 60 at the projections 67 so as to facilitate aninterference fit between the gauge insert 60 and the side walls of theslot 62. The projections 67 may be made of a different material than theother portions of the gauge insert 60.

The gauge insert 60 may also have a recess or hole 66 suitably sized toreceive the tip of an implement such as a flat head screwdriver or thelike after the gauge insert 60 has been inserted in the slot 62. Therecess or hole 66 may be positioned, for example, as shown in FIG. 9 topermit access from above the slot 62. This allows the installer toeasily insert the tip of the implement into the recess or hole 66 andlift the gauge insert 60 out of the slot 62. The gauge insert 60, oranother gauge insert 60, may subsequently be inserted into the slot 62in the same or a different orientation such that the gauge insert 60 isoriented for the use of the appropriate longitudinal dimension D1, D2,D3, D4 for the thickness of the associated door 100.

Referring now to FIGS. 2, 4 and 6-8, details of the illustratedretention member 50 and its cooperative anti-rotational relationshipwith the lock chassis 10 and the anti-rotation plate 22 will now bedescribed. The retention member 50 may comprise a resilient materialsuch as, for example, a plastic or rubber. The retention member 50slides into a receptacle 47 of the inside hub 48 of the lock chassis 10along a longitudinal axis L (FIG. 8) that is parallel to the axis ofrotation R of the door handle 18. The anti-rotation plate 22 in turnslides over the inside hub 48 and the retention member 50 so that theretention member 50 frictionally engages and/or resists axial movementof the anti-rotation plate 22 relative to the inside hub 48. As such,the retention member 50 retains the anti-rotation plate 22 on the lockchassis 10 at a mount position.

Turning to FIG. 8, the receptacle 47 of the inside hub 48 defines a pairof opposite facing longitudinally extending channels 47 a and a cavity47 b between and radially inwardly of the channels 47 a. The receptacle47 includes a ramp portion 47 c axially adjacent to the cavity 47 b. Theramp portion 47 c has an inclined surface in the longitudinal directionfrom the inside to the outside or right to left in FIG. 7. The retentionmember 50 includes a base 53 which has opposite lip portions 53 a thatare slideable within the channels 47 a of the receptacle 47. Theretention member 50 includes a retention nodule 52 (shown in FIG. 7)that projects downward from the base 53 and is sized to fit in thecavity 47 b of the receptacle 47.

To install the retention member 50 in the lock chassis 10, an installerslides the base 53 of the retention member 50 into the channels 47 a ofthe receptacle 47 until the retention nodule 52 contacts the rampportion 47 c. The installer then pushes the retention member 50 to urgethe retention nodule 52 over the ramp portion 47 c and into the cavity47 b of the receptacle 47. Due to the resilient characteristics of theretention member 50, as the retention nodule 52 is axially urged overthe ramp portion 47 c, the retention member 50 bends or flexes slightlyradially outward. As the retention nodule 52 is urged beyond the rampportion 47 c, the retention member 50 flexes or snaps back radiallyinward to its original unflexed state so that the retention nodule 52 isthen captured inside the cavity 47 b. As shown in FIG. 8, the radiallyouter walls of the channels 47 a resist radially outward movement of thebase 53 from the receptacle 47, and the back side of the ramp portion 47c resists rearward longitudinal movement (to the right in FIG. 7) of theretention nodule 52 from the cavity 47 b. As such, the receptacle 47secures the retention nodule 52 in the lock chassis 10.

Referring now to FIGS. 7 and 8, the retention member 50 includes aplurality of resilient members 54, which in the illustrated embodimentcomprise longitudinally spaced wall members. The resilient members 54project radially outward from the base portion 53 beyond the outsidesection 30 of the inside hub 48, as illustrated in the FIG. 4embodiment. As shown in FIG. 7, the anti-rotation plate 22 includes aradially inner flange 22 a, a radially outer flange 22 b, and an annularportion 22 c there between connecting the inner flange 22 a and theouter flange 22 b. The inner flange 22 a has an interior opening 20which in the illustrated embodiment is somewhat oblong octagon shaped.The interior opening 20 is shaped to correspond to the shape of theoutside section 30 of the inside hub 48. The corresponding shapedinterior opening 20 in the inner flange 22 a and the outside section 30of the inside hub 48 may have a function of ensuring that theanti-rotation plate 22 is installed on the lock chassis 10 in the properangular orientation.

As shown in FIGS. 6 and 7, the inner flange 22 a of the anti-rotationplate 22 at the location 25 corresponding to that of the resilientmembers 54 of the retention member 50 is radially inward relative to thedistal ends of the resilient members 54. As such, during installation ofthe anti-rotation plate 22 on the inside hub 48 of the lock chassis 10,the inner flange 22 a comes into contact with the resilient members 54.As the installer axially urges the anti-rotation plate 22 over theresilient members 54, the inner flange 22 a bends or flexes theresilient members 54 radially inward of the inner flange 22 a to comeinto frictional engagement with the resilient members 54. The resilientmembers 54, in turn, counteract the force exerted by the inner flange 22a, and exert a radially outward force against the inner flange 22 a tocome into frictional engagement with the inner flange 22 a, and thus theanti-rotation plate 22. This frictional engagement retains theanti-rotation plate 22 on the inside hub 48 of the lock chassis 10. Theinstaller is then free to install the remaining portions of the lockassembly 15 without concern for the lock chassis 10 disengaging from thedoor 100.

In the FIG. 7 embodiment, the anti-rotation plate 22 is in abuttingrelation with a backstop 55 of the inside hub 48. As the anti-rotationplate 22 is urged over the resilient members 54, the resilient members54 that are axially behind the inner flange 22 a flex or snap backradially outward to their original unflexed state. In an embodiment,these resilient members 54 resist rearward axial movement of theanti-rotation plate 22.

According to certain embodiments, the retention member 50 has noresilient members 54 near the backstop 55. Thus, there are no resilientmembers 54 that exert a radially outward force against the inner flange22 a of the anti-rotation plate 22 when the anti-rotation plate 22 is inabutting relation with the backstop 55, and instead the resilientmembers 54 that are axially behind the inner flange 22 a and have flexedor snapped back radially outward to their original unflexed state,resist rearward axial movement of the anti-rotation plate 22.

In the embodiment shown in FIGS. 6-8, the inner flange 22 a of theanti-rotation plate 22 at the location 25 corresponding to that of theresilient members 54 of the retention member 50 is substantially alignedwith the radially outer wall of the channels 47 a. The inner flange 22 ais not limited to the form illustrated in FIGS. 1, 6 and 7; otherembodiments are also contemplated herein. For example, in an embodiment,the inner flange 22 a is not substantially aligned with the radiallyouter wall of the channels 47 a and/or has a nonlinear or curvedconfiguration.

As described, the resilient members 54 exert a force against the innerflange 22 a to come into frictional engagement with the inner flange 22a to retain the anti-rotation plate 22 on the inside hub 48 of the lockchassis 10. In an embodiment, the resilient members 54 exert a forceagainst the inner flange 22 a such that a location of the inner flange22 a other than the location 25, for example a location that isdiametrically opposite the location 25, comes into frictional engagementwith the inside hub 48 of the lock chassis 10. Thus, the retentionmember 50 frictionally engages the lock chassis 10 at one location, forexample location 25, and also urges the anti-rotation plate 22 intofrictional engagement with the lock chassis 10 at another location.These frictional engagements together retain the anti-rotation plate 22on the inside hub 48 of the lock chassis 10.

Any theory, mechanism of operation, proof, or finding stated herein ismeant to further enhance understanding of embodiment of the presentinvention and is not intended to make the present invention in any waydependent upon such theory, mechanism of operation, proof, or finding.In reading the claims, it is intended that when words such as “a,” “an,”“at least one,” or “at least one portion” are used there is no intentionto limit the claim to only one item unless specifically stated to thecontrary in the claim. Further, when the language “at least a portion”and/or “a portion” is used the item can include a portion and/or theentire item unless specifically stated to the contrary.

While embodiments of the invention have been illustrated and describedin detail in the drawings and foregoing description, the same is to beconsidered as illustrative and not restrictive in character, it beingunderstood that only the selected embodiments have been shown anddescribed and that all changes, modifications and equivalents that comewithin the spirit of the invention as defined herein of by any of thefollowing claims are desired to be protected. It should also beunderstood that while the use of words such as “preferable”,“preferably”, “preferred” or “more preferred” utilized in thedescription above indicate that the feature so described may be moredesirable, it nonetheless may not be necessary and embodiments lackingthe same may be contemplated as within the scope of the invention, thescope being defined by the claims that follow.

1. A door lock chassis adapted to be mounted within doors havingdifferent door thicknesses, the door lock chassis comprising: a lockbody having a slot; an adjustment plate adapted to be adjustably mountedto the lock body; and a removable gauge insert adapted to frictionallyengage the adjustment plate and to be received in the slot at one of aplurality of positive stop arrangements, each of the plurality ofpositive stop arrangements configured to, when the adjustment plate isoperably mounted to the lock body, separate the adjustment plate from aportion of the lock body by an axial distance, the axial distance beingdifferent for each of the plurality of positive stop arrangements. 2.The door lock chassis of claim 1, wherein the adjustment plate includesan annular portion having an edge, the annular portion configured forthe edge to contact one of a plurality of positive stops of theremovable gauge insert when the adjustment plate is separated from aportion of the lock body by the axial distance.
 3. The door lock chassisof claim 2, wherein the annular portion includes an interior thread, andwherein the frictional engagement between the adjustment plate and theremovable gauge insert is a threaded engagement between the interiorthread and the removable gauge insert.
 4. The door lock chassis of claim1, wherein the removable gauge insert includes a plurality of legs and aplurality of positive stops, and wherein each of the plurality ofpositive stop arrangements include a longitudinal distance, thelongitudinal distance being a distance between one of the plurality ofpositive stops and an end of a non-adjacent leg of the plurality oflegs, the longitudinal distance being different for each of theplurality of positive stop arrangements.
 5. The door lock chassis ofclaim 4, wherein the plurality of positive stops comprises four positivestops.
 6. The door lock chassis of claim 4, wherein the removable gaugeinsert provides an indicia of the axial distance for each of theplurality of positive stop arrangements.
 7. The door lock chassis ofclaim 6, wherein the indicia for at least one of the plurality ofpositive stop arrangements has a different shape than the indicia for atleast another of the plurality of positive stop arrangements.
 8. Thedoor lock chassis of claim 7, wherein the different shape issubstantially an arrow shape.
 9. The door lock chassis of claim 4,wherein the adjustment plate further includes a flange adapted tocontact a face of the door when the body portion is positioned in amounting hole in the door, the flange having a plurality of aperturesarranged for alignment with supplemental mounting holes in the door. 10.A door lock chassis adapted to be mounted within doors having differentdoor thicknesses, the door lock chassis comprising: a body portionhaving at least one slot; an adjustment plate adapted to be adjustablymounted to the lock body; and at least one gauge insert adapted to beremovably received in the at least one slot, the at least one gaugeinsert having a first portion and a second portion, the first portionadapted to provide an axial position for the adjustment plate relativeto at least the body portion, the second portion adapted to frictionallyengage the adjustment plate to resist movement of the adjustment plateaway from the axial position.
 11. The door lock chassis of claim 10,wherein the first portion includes a plurality of positive stops and thesecond portion includes a plurality of legs.
 12. The door lock chassisof claim 11, wherein each of the plurality of positive stops areseparated from a non-adjacent leg of the plurality of legs by alongitudinal distance, the longitudinal distance being different foreach of the plurality of stops, and wherein each of the positive stopsare positioned for the first portion to be configured to provide aplurality of axial positions for the adjustment plate.
 13. The door lockchassis of claim 10, wherein the second portion is frictionally engagedwith an annular portion of the removable insert by a threadedengagement, and wherein the second portion includes a chamfer configuredto facilitate the threaded engagement.
 14. The door lock chassis ofclaim 10, wherein the lock body is configured to be positioned in thedoor between an interior handle and an exterior handle for operating alatch.
 15. An anti-rotational assembly for a door lock having a lockchassis, the anti-rotational assembly comprising: an inside hub of thelock chassis, the inside hub having a receptacle that includes a cavityand a pair of channels, the pair of channels configured tolongitudinally extend along opposing sides of the cavity; a retentionmember having a base and one or more resilient members, the base havinga pair of lips that are adapted to be slidingly received in the pair ofchannels; and an anti-rotation member configured for a slidingengagement with the one or more resilient members in a first axialdirection as the anti-rotation member is displaced to an mount positionrelative to the inside hub, the anti-rotation member being furtherconfigured to be retained in the mount position by a frictionalengagement between the anti-rotation member and with the one or moreresilient members.
 16. The anti-rotational assembly of claim 15, whereinthe retention member further includes a retention nodule, and furtherwherein the receptacle includes a ramp portion for axially guiding theretention nodule into the cavity, the ramp portion having a wallconfigured to resist displacement of the retention member from thecavity.
 17. The anti-rotational assembly of claim 15, wherein the one ormore resilient members comprise one or more radially outward projectingwalls that are longitudinally spaced apart.
 18. The anti-rotationalassembly of claim 15, wherein the anti-rotation member includes an innerflange having an opening that corresponds in shape to an outside sectionof the inside hub.
 19. The anti-rotational assembly of claim 15, whereinthe anti-rotation member includes an inner flange having an opening thatcorresponds in shape to a peripheral portion of the inside hub, andwherein the one or more resilient members are in frictional engagementwith the inner flange.
 20. An anti-rotational assembly for a door lockhaving a lock body, the anti-rotational assembly comprising: an insidehub of the lock body, the inside hub having an outer section; aretention mechanism secured to the inside hub, the retention mechanismhaving one or more resilient members; and an anti-rotation memberconfigured to deflect the one or more resilient members as theanti-rotation member is displaced in a first axial direction, and to beretained in a mount position on the inside hub by a frictionalengagement with the one or more resilient members.
 21. Theanti-rotational assembly of claim 20, wherein the anti-rotation memberincludes an inner flange, and outer flange, and a annular portion, theinner flange being separated from the outer flange by the annularportion, and wherein the one or more resilient members exert a forceagainst the inner flange to retain the anti-rotation member in the mountposition.
 22. The anti-rotational assembly of claim 20, wherein the oneor more resilient members comprise radially outward projecting wallsthat are longitudinally spaced apart.
 23. The anti-rotational assemblyof claim 20, wherein the inside hub includes a receptacle in which theretention member is secured relative to the inside hub.
 24. Theanti-rotational assembly of claim 23, wherein the receptacle includes apair of channels and the retention member includes a base portion thatis slideable in the pair of channels.
 25. The anti-rotational assemblyof claim 24, wherein the receptacle includes a cavity and a ramp portionfor axially guiding a nodule of the retention member into the cavity,and the ramp portion includes a wall that resists movement of theretention member from the cavity.